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PERFORMANCE CATALOG VOL 8 Turbochargers | Intercoolers | Accessories TABLE of CONTENTS OUR HISTORY

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PERFORMANCE CATALOG VOL 8 Turbochargers | Intercoolers | Accessories TABLE of CONTENTS OUR HISTORY PERFORMANCE CATALOG VOL 8 Turbochargers | Intercoolers | Accessories TABLE OF CONTENTS OUR HISTORY The heritage of our turbo business began in 1936 when young Cliff Garrett formed his company in a tiny, one-room office in Los Angeles. Cliff founded the company that would later become the Garrett Corporation. Number of employees, 1. Number of customers, 1. In the WHY CHOOSE GARRETT 04 1950s, it successfully added boosting a Caterpillar C9 tractor signaling the birth of automotive turbocharging. 07 HOW TO READ A COMPRESSOR MAP Through names such as AiResearch, AlliedSignal, Honeywell Transportation Systems, and 09 TROUBLESHOOTING now Garrett Advancing Motion, the business has sustained a reputation for revolutionizing turbocharger technologies generation after generation. From the world’s first turbocharged production car – the Oldsmobile Jetfire Rocket - to the first Garrett turbocharged car to win 10 G SERIES TURBOCHARGERS the Indianapolis 500, Garrett's industry-leading technology and patented designs are used daily for both OE and aftermarket vehicle applications. 26 GTX SERIES TURBOCHARGERS Garrett turbocharger technology is the preferred choice for leading original equipment manufacturers including: Audi, BMW, GM, Daimler Chrysler, Mercedes, DDC, Fiat, Ford, 46 GTW SERIES TURBOCHARGERS International Truck Co, Peugeot, Renault, Saab, and Volkswagen. Top race teams in Formula 1, World Rally, American Le Mans, 24 Hours of Le Mans, Formula Drift, Global Time Attack, NHRA, Radial vs the World Drag Racing, X275, and Pikes Peak Hill Climb rely on Garrett turbo 52 GT SERIES TURBOCHARGERS technology to keep them on the podium. ACCESSORIES Today, our Garrett legacy in both Aerospace and automotive industries helps create some of 64 the most innovative and high-performing turbochargers in the world that can enable a four cylinder turbocharged engine to perform like a non-turbocharged V6 engine while providing 66 VEHICLE SPECIFIC TURBOCHARGERS 20-40% greater fuel efficiency. Garrett's global engineering network continues to inspire technological innovation around the world. 76 PERFORMANCE INTERCOOLERS CONFIGURATION GUIDE The products contained in this catalog are performance aftermarket parts that are not legal for street 85 use in certain states or countries, unless a type-approval/executive order has been obtained e.g. by the distributor of the product. Check with your distributor before using in any vehicle on a public road or highway. You should check with your state or applicable country authorities to find out whether these 86 TURBO INDEX products are legal for street use in your state or country. Applicable laws may also prohibit tampering with parts or vehicle design elements affecting emissions on vehicles intended for use on public roads. You are responsible for ensuring that the use of this product complies with all applicable laws, regulations and ordinances (including, but not limited to, emission, noise, safety, and type-approval/ executive order). Any vehicle modifications using the products in this catalog are completed AT YOUR OWN RESPONSIBILITY and AT YOUR OWN RISK. A vehicle modification using these performance aftermarket products may affect or void a vehicle's warranty, operating license/registration or type-approval/executive order. You should consult your local laws, as well as the owner’s manual and service manual of your vehicle. You should also contact your vehicle’s manufacturer to determine what effect modifications may have on safety, warranty, performance, and other aspects of your vehicle. These products generally may be used on racing vehicles that will never be driven on public roads or highways. 2 3 HOW A TURBO SYSTEM WORKS Engine power is proportional to the amount of air and fuel that can get into the cylinders. All things being equal, larger engines flow more air and as such will produce more power. If we want our small engine to perform like a large engine, or simply make our larger engine produce more power, our ultimate objective is to deliver more air into the cylinder. By installing a Garrett turbocharger, the power and performance of an engine can be dramatically increased. HOW DOES A TURBOCHARGER DELIVER MORE AIR INTO THE ENGINE? (1) Compressor Inlet: Opening through which ambient air passes before entering the compressor. (2) Compressor Discharge: Ambient air is then compressed which raises the air’s density (mass/unit volume). (3) Charge Air Cooler (aka Intercooler): cools the compressed air to increase its density and to increase resistance to detonation. (4) Intake Manifold: Directs dense air into the engine’s cylinders. Each cylinder draws in an increased mass flow rate of air. Higher air mass flow rate allows a higher fuel flow rate (with similar air/fuel ratio). Combusting more fuel results in more power for a given displacement. WHY CHOOSE GARRETT TURBOCHARGERS (5) Exhaust Manifold: Directs burned fuel and exhaust gasses from the cylinders towards the turbine. (6) Turbine Inlet: Directs high temperature exhaust gas towards the turbine wheel. The turbine creates backpressure on the engine which means engine exhaust pressure is higher than atmospheric pressure. (7) Turbine Discharge: A pressure and temperature drop occurs (expansion) across the turbine, which harnesses the exhaust A turbo is a high technology product that requires superior design and intensive capital to produce. It must meet severe gas’ energy to provide the power necessary to drive the compressor wheel. requirements that only a world class manufacturer can achieve. Garrett is one of the few turbocharger manufacturers that subjects our turbos to several OE qualification tests. These tests ensure Garrett produces a safe and reliable turbo for OE applications. When you buy a Garrett turbocharger you can be sure it is reliable. On-Engine Durability – More than 1,000-hours of general turbocharger durability, is run on-engine in one of Garrett's engineering laboratories. Gas Stand Cyclic Durability – A several hundred hour durability test is conducted on a gas stand where the turbo is run past it normal operating limits. Compressor & Turbine Housing Containment - A compressor/turbine wheel is weakened to hub burst at a specific speed. No portion of the wheel is allowed to penetrate a containment shroud surrounding the turbocharger. A test to ensure safety. See full article at www.GarrettMotion.com Shaft Motion - The maximum tolerances of the bearing system are tested for rotordynamic stability beyond the maximum turbocharger operating speed. This means no bearing problems and a long turbo life. Thrust Bearing Capacity - A test that stresses the thrust bearing at extreme conditions. This test makes sure your Garrett turbocharger can tolerate the load you put it through. Compressor & Turbine Seal - Multiple turbochargers are run on-engine under conditions designed to cause seal leakage. No significant leakage is allowed during these tests. Heat Soakback - A turbocharger instrumented with thermocouples is taken beyond maximum operating temperature and shut down hard! Repeat the test four more times and make sure maximum temperatures stay within our strict limits to avoid oil coking COMPONENTS OF A TURBOCHARGER or build up inside the center housing. This is particularly critical for high temperature gasoline applications. Compressor & Turbine Performance - The entire operating range of both the compressor and turbine are mapped on one of Garrett's performance gas stands. These test cells are calibrated to strict standards to assure accuracy and consistency. Compressor & Turbine Blade Frequencies - Garrett has strict requirements for compressor and turbine blade natural frequency. This is critical on large trims where the blade must be stiff enough to withstand potentially damaging vibrations. Thermal Cycle - A several hundred hour endurance test that cycles the turbocharger from low temperature to glowing red every 10 minutes. To ensure a long turbo life, no cracking of the turbine housing or distortion of the heat shroud are allowed. Rotor Inertia - A measurement made to document the rotational inertia of Garrett's compressor and turbine wheels. Garrett's turbochargers are known for their high flow / low inertia characteristics. Shaft Critical Speed - An analytical test that ensures that destructive shaft critical speeds are well out of the turbocharger operating range. For example, large wheels may require a large shaft diameter to avoid the shaft bending critical speed. Wheel Fatigue - Garrett will only sell compressor or turbine wheels that have passed a cyclic fatigue test. Garrett runs tests on a regular basis to ensure quality and to constantly improve our products. Turbo Vibration - The entire turbocharger is vibrated and monitored on Garrett's large shaker table to ensure product durability. 4 5 DUAL BALL BEARING HOW TO READ A COMPRESSOR MAP Ball bearing innovation began as a result of work with the The compressor map describes each compressor’s performance characteristics, including efficiency, mass flow rate, turbo speed, Garrett Motorsports group for several racing series where it choke line, surge line, and pressure ratio. Below is a figure that identifies these aspects. received the term the “cartridge ball bearing”. The cartridge is a single sleeve system that contains a set of angular contact Efficiency Islands: Efficiency Islands are concentric regions that represent the compressor efficiency at any point on the map. The ball bearings on either end, whereas the traditional bearing smallest island near
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